Share Email Print

Proceedings Paper

Improving accuracy of overhanging structures for selective laser melting through reliability characterization of single track formation on thick powder beds
Author(s): Sankhya Mohanty; Jesper Henri Hattel
Format Member Price Non-Member Price
PDF $14.40 $18.00

Paper Abstract

Repeatability and reproducibility of parts produced by selective laser melting is a standing issue, and coupled with a lack of standardized quality control presents a major hindrance towards maturing of selective laser melting as an industrial scale process. Consequently, numerical process modelling has been adopted towards improving the predictability of the outputs from the selective laser melting process. Establishing the reliability of the process, however, is still a challenge, especially in components having overhanging structures.

In this paper, a systematic approach towards establishing reliability of overhanging structure production by selective laser melting has been adopted. A calibrated, fast, multiscale thermal model is used to simulate the single track formation on a thick powder bed. Single tracks are manufactured on a thick powder bed using same processing parameters, but at different locations in a powder bed and in different laser scanning directions. The difference in melt track widths and depths captures the effect of changes in incident beam power distribution due to location and processing direction. The experimental results are used in combination with numerical model, and subjected to uncertainty and reliability analysis. Cumulative probability distribution functions obtained for melt track widths and depths are found to be coherent with observed experimental values. The technique is subsequently extended for reliability characterization of single layers produced on a thick powder bed without support structures, by determining cumulative probability distribution functions for average layer thickness, sample density and thermal homogeneity.

Paper Details

Date Published: 6 April 2016
PDF: 14 pages
Proc. SPIE 9738, Laser 3D Manufacturing III, 97381B (6 April 2016); doi: 10.1117/12.2212621
Show Author Affiliations
Sankhya Mohanty, Technical Univ. of Denmark (Denmark)
Jesper Henri Hattel, Technical Univ. of Denmark (Denmark)

Published in SPIE Proceedings Vol. 9738:
Laser 3D Manufacturing III
Bo Gu; Henry Helvajian; Alberto Piqué, Editor(s)

© SPIE. Terms of Use
Back to Top